case cx 210 exc trainnig service

Construction Equipment Service Training

Section 1 --GENERAL INTRODUCTIONCNH EngineDiagnostic Class

CX SERIESEXCAVATOR

(2004)

CNH America LLC 2004700 STATE STREET All Rights ReservedRACINE, WI 53404 U.S.A. Printed in U.S.A.

GENERAL INTRODUCTION

1 - 1 CX EXCAVATORS

TABLE OF CONTENTS

Section 1 - General Introduction

PAGE NO.

Engines ...................................................................................................................... 2Reservoir.................................................................................................................... 3Filters ......................................................................................................................... 3Pumps........................................................................................................................ 4Pilot System ............................................................................................................... 5Hydraulic Systems ..................................................................................................6-7Cushion Control ......................................................................................................... 7Swing ......................................................................................................................... 7Travel .........................................................................................................................8Cylinders .................................................................................................................... 9Electrical System.................................................................................................10-11


1 - 2 CX EXCAVATORS

EXPLANATION OF CX SERIES

EnginesMODEL CX130 CX160 CX210 CX240MakeModel

CASE4TA390

CASE4TA390

CASE6TAA590

CASE6TAA590

HP (net) 106 106 138 163

Cold Start Ether Ether Electric Electric

Rated rpm 2200 2200 1950 2150

When programming the excavators, the manufacture model number must be used. Detailedprocedures are in section 3 of this training manual.

Manufacturemodel number

Casemodel number

SHO120 CX130SHO150 CX160SHO200 CX210SHO220 CX240

When programming the excavators, the following codes will be used to change the languageif necessary. Detailed procedures are in section 3 of this training manual.

LANGUAGEMODE

NO. LANGUAGEMODE

NO. LANGUAGE MODE

NO.

Japanese 0 Italian 6 Swedish 12

English 1 Spanish 7 Finnish 13

Thai 2 Portuguese 8 Picture writing 14

Chinese 3 Dutch 9

German 4 Danish 10

French 5 Norwegian 11


1 - 3 CX EXCAVATORS

EXPLANATION OF CX SERIESReservoirThe reservoir is pressurized on all models. The air charge is provided by thermal expansionand the differential area of the cylinders as they are stroked the first time. There is abreather/pressure regulator/fill cap installed in the top cover of the excavators. A rubber-covered button on top of the breather is provided to release the air pressure in the reservoir.A sight gauge mounted to the side of the reservoir indicates the oil level. There is a 150-meshscreen at the outlet of the reservoir to the hydraulic pump.

ReservoirMODEL CX130 CX160 CX210 CX240CapacityTank gal.

19 32 32 32

CapacitySystem gal.

32 38 54 59

FiltersThe oil returning from the main control valve flows through the oil cooler. There is a coolerbypass valve in the circuit to protect the system during cold start conditions. As the oil returnsfrom the oil cooler, it passes through a full flow 10-micron filter. Some of the return oil isrouted through a 1-micron ultra-fine filter. Drain oil from the pilot control circuits and the casedrain oil from the swing and travel motors is returned through the main return filter. A cartridge type filter is installed in the outlet of the pilot pump to protect all pilot valves fromcontamination. All of these filters have filter bypass valves for cold start up protection.

FiltersMODEL CX130 CX160 CX210 CX240Suction 150 mesh 150 mesh 150 mesh 150 mesh

Return 10 µ 10 µ 10 µ 10 µ

Ultra-fine 1 µ 1 µ 1 µ 1 µ

Pilot 10 µ 10 µ 10 µ 10 µ


1 - 4 CX EXCAVATORS

EXPLANATION OF CX SERIESVariable PumpsAll of the CX Series Excavators use an open center hydraulic system, in that there is alwaysan output flow from the hydraulic pump flowing through the system. The CX SeriesExcavators use a variable flow piston pump system to be able to fully use the enginehorsepower. As the system operating pressure increases, the flow gradually reduces, tomaintain a constant horsepower load on the engine. The theory is that when very highpressures are required, speed isn't so important. The CX Series Excavators use a two-section variable displacement piston pump, to provide the flow required to operate thefunctions. Variable pumps allow the delivery of higher flow rates at lower working pressures,and then allow the pumps to reduce the flow at higher pressures, to keep from stalling theengine. The increased flow at lower pressures makes the cycle times faster, and increasesthe overall efficiency of the excavator.The engine horsepower required to drive a hydraulic pump depends on the flow delivered bythe pump, as well as the pressure at which system is operating. There is a mathematicalformula to calculate the pump drive horsepower, but a rule of thumb to visualize this, is that itrequires approximately 1 engine horsepower to deliver 1 gallon per minute of oil at 1500 psi.Therefore, it would require 25 HP to deliver 25 GPM at 1500 psi. If the pressure increases to3000 psi, the requirement would be 50 HP.The CX Series Excavators have an automatic pump de-stroke feature that reduces the pumpflow to a minimum, when all control levers are in the neutral position. This is accomplishedwith a hydraulic pilot signal from the control valve. This system saves fuel and eliminateswasted engine and hydraulic power. The minimum flow delivery of the pumps increases withexcavator size and engine horsepower. Although the pump configuration and manufacturervaries, in principal, all of the pump control systems operate the same.

PumpsMODEL CX130 CX160 CX210 CX240

Max. pump flowX 2

32.4 gpm 36.2 gpm 53.1 gpm 56 gpm

Pilot pump flow 6 gpm 5.8 gpm 5.3 gpm 5.3 gpm

Manufacture Uchida/Kawasaki

Uchida/Kawasaki

Kawasaki Kawasaki

Configuration Tandem Tandem Tandem Tandem


1 - 5 CX EXCAVATORS

EXPLANATION OF CX SERIESPilot ControlsThe attachment controls are pilot operated by hand actuated controllers on all models. Thepilot hand controls are mounted to tilting armrests that can be positioned to provide formaximum operator comfort. The standard control pattern is the SAE pattern. The controls canbe changed to other configurations by changing the pilot hose connections at the pilotmanifold, located behind the cab (see Section 8001 of the Service Manual for instructions). There is a pattern change kit available as an option which allows pattern changes withoutmoving hoses.

When the left arm is tilted up or the gate lever is up, all pilot operated control functions areinactive. On all models, the travel system is actuated by foot pedals that also have hand control leversattached. The travel controls are pilot pressure operated on all models. The CX240 – CX800have a single pedal feature. By actuating a single control pedal, both travel motors will travelat the same speed and direction. This feature gives the operator straight-line travel in eitherforward or reverse.

Pilot ControlsMODEL CX130 CX160 CX210 CX240Pilotoperatedhand andfoot controls

yes yes yes yes

Single pedaltravel

no no no yes


1 - 6 CX EXCAVATORS

EXPLANATION OF CX SERIESHydraulic System OverviewAll models use a triple hydraulic pump assembly that is located on the same side of theexcavator as the reservoir. All of the excavators use two variable displacement piston pumpsfor the excavator functions. A fixed displacement gear pump used to supply pilot control oilfor the system. The original CX130 and CX160 excavators used a tandem mounted pumpsupplied by Uchida. All later excavators use a tandem mounted pump supplied by Kawasaki.All of the pumps have a system to limit the horsepower load on the engine. This systemallows the excavator to fully utilize the power available without overloading the engine. TheCX Series Excavators have an electrically controlled feature that allows the hydraulic systemto operate at less than full load to increase fuel economy or fine touch controllability. This feature allows for four digging modes: “Auto” -Variable- 90-85% engine speed- 93-90% hydraulic pump torque."H" -Heavy Duty - 100% of engine speed - 100% hydraulic pump torque."S" -Standard Duty - 95% of engine speed - 90% hydraulic pump torque."L" -Light - 85% of engine speed - 70% hydraulic pump torque.The original excavators were in the “Auto” mode each time they were started, newer modelsdefault to the “H” mode.All models have Power Boost.CX130/CX160 excavators have One-Touch Power Boost.CX210/CX800 excavators have automatic Power Boost.


1 - 7 CX EXCAVATORS

EXPLANATION OF CX SERIESThe CX Series Hydraulic SystemThere is a single main relief with a second (power boost) setting. Boom and arm anti-driftvalves are built into the main control valve. An auxiliary control valve is standard and a factoryinstalled or field installed kit with plumbing to the end of the arm is available. Other featuresthat are built into the main control valve are:

Dual pump flow boom upBoom down regenerationBoom down anti-driftDual pump flow arm in and outArm in regenerationArm in anti-driftTravel prioritySwing priorityNeutral pump de-stroke

Two electrical pressure switches are installed on the main control valve, and one in the swingpilot shuttle valve. These switches are used to tell the controller what hydraulic functions arebeing operated.

Cushion Control SystemThe CX Series excavators have an attachment control cushion system to allow the boom andarm cylinder control spools to gradually return to neutral, for shock-free operation. Thisfeature allows a lesser skilled operator to work more smoothly. With the control cushionsystem active, the pilot oil from the hand control flows to the arm or boom control spoolunrestricted. When the hand control is returned to neutral, the pilot oil is restricted as itleaves the control spool. This slow return of the spool accounts for the smooth operation.The system can be overridden with an electrical control switch on the monitor/switch panel.

SwingThe CX Series Excavators do not have a mechanical house lock. The house lock isaccomplished with the swing brake. The swing brake is applied when the switch on the leftconsole is activated or the engine is shut off. The swing brake is also applied 5 seconds afterthe hand control is returned to neutral unless “Free-Swing” is turned on.


1 - 8 CX EXCAVATORS

EXPLANATION OF CX SERIESTravel CX130/CX160/CX210/CX240/CX290/CX330/CX460/CX800The travel motors are located at the rear of each track assembly. The travel system iscontrolled by control spools in the main control valve located in the excavator upper section.The travel drive system has independent, compact, axial piston, two speed hydraulic motors.Each track is independently driven by a sprocket, which is driven by a planetary reductiongear. There is a spring applied, hydraulically released disc brake built into each motor. Thetravel brake is released by the travel pressure applied to the motor. Each travel motor isequipped with a counterbalance valve and a dual stage relief valves for smooth starts andstops. The counterbalance valve prevents over speeding of the motor while driving down anincline. The shockless relief valve allows for additional cushioning in the circuit by allowing aslight transfer of oil between travel directions as the excavator is started and stopped. Thetravel motors and planetary gears are mounted within the width of the side frame. Two-speedtravel is controlled by the controller, which controls a solenoid valve. The travel speedsolenoid supplies pilot system pressure to actuate the two-speed spool in each travel motor.Travel drive pressure is then ported through the two-speed control spool to the motor swashplates. The excavators are in “LOW SPEED” travel when the key is turned on. When thetravel switch is depressed, the excavator will be in “HIGH SPEED” and if the drive load is toohigh, the motor will automatically shift to “LOW SPEED”, and back to “HIGH SPEED” whenthe load is reduced. The Dash still indicates “HI”, the change takes place in the motors.The travel system has a travel priority valve to insure straight travel, if the swing function, orany attachment function is activated, while traveling. When traveling without other functionsactivated, one pump supplies right travel with the other pump supplying left travel. When thetravel priority spool shifts, because of multiple function application, one pump is used tosupply both right and left travel, while the other pump is used for the attachment functions.With one pump supplying, both travel functions, the travel speed will naturally be reducedsignificantly.

Travel

MODEL CX130 CX160 CX210 CX240

L Speed 2.1

H Speed 3.4


1 - 9 CX EXCAVATORS

EXPLANATION OF CX SERIESCylindersThe attachment cylinders have a cushion feature to hydraulically reduce the speed of thecylinder rod at the extreme ends of travel to limit the shock on the excavator. Bucket openand boom down cylinder positions do not have cushions.


1 - 10 CX EXCAVATORS

EXPLANATION OF CX SERIESElectrical SystemAll models have a 24-volt starting and charging system. The CX Series Excavators have two12-volt batteries, wired in series to obtain the 24-volt capacity. These batteries are located inthe compartment behind the cab.There is a battery relay connected between the positive battery cable and the excavatorelectrical system. The battery relay acts as the master disconnect for the system. The batteryrelay closes as the key switch is turned to the "on" position.



EXPLANATION OF CX SERIESElectrical SystemTo improve engine starting during cold temperatures, the CX130 and CX160 are equippedwith an ether injection system as standard equipment. The ether injection system can only beactivated when the key-switch is in the crank position. There is a rocker switch located on theleft-hand control console for easy access to the operator. There is also a temperature switchlocated on the engine intake manifold to prevent engagement of the ether system when theengine is above 40°F (5°C). On the CX210, CX240, CX290 and CX330, there is an intakemanifold heater for cold starting assistance, which is turned on with the key switch. TheCX460 and CX800 engines use glow plugs in each cylinder to aid cold weather starting.

The Alternator is rated at 24 volts. The electronic controller for the CX130/CX160 excavatorsrequire an engine speed signal from a magnetic sensor on the flywheel. This engine speedsignal is extremely critical to excavator functions. The other CX excavators have electroniccontrolled engines. The excavator controller requires input from the engine controller.

The engine, the hydraulic, and the electrical systems are all monitored by a controller. Thecontroller for the CX130/CX160 is different than for the CX210/CX240. The controllerreceives signals from sending units. Very simply, the controller takes the information that ithas received, and then sends the required outputs to cause the excavator to perform asselected. These outputs may be sent to the display panel to indicate a malfunction or to givea visual display of which performance features have been selected. The outputs may also besent to the solenoid valves, which control the excavator functions. The controller has anautomatic “limp home” feature to allow the excavator to be operated to complete the job incase of controller failure.



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CX130 Theoretical Pump Flow L, S & H ModeTSG - Technical Service Group 01 - 01

33.7

27.2

23.2

20.5

17.916.3

13.712.1

30.8

19.2

16.914.9

9.9

25.3

22.4

19

16.5

119.9

7.9

33.7

11.2

13.5

22.2

25.6

30.8

8.3

12.414.1

29.229.2

0

5

10

15

20

25

30

35

40

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000

Pressure (PSI) = P1 + P2

Flow

= (G

PM)

H Mode 2130 RPMS mode 1950 RPML Mode 1850 RPM

H Mode mA = 600S Mode mA = 450


35

0

5

10

15

20

25

30

35

40

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000


Flow

= (G

PM)

H Mode 2130 RPMS mode 1950 RPML Mode 1850 RPM

H Mode mA = 600S Mode mA = 450

CX160 Theoretical Pump Flow L, S, & H ModeTSG - Technical Service Group 01 - 01

37.7 37.7

31

26.7

23.2

20.618.8

15.313.7

34.7 34.7

29.6

25.6

21.8

19.217.2

15.3

12.711.2

33.0 33.0

29.1

25.6

21.7

18.9

16.1

14.012.4

11.29.5

8.1

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000


Flow

= (G

PM)

H Mode 2230 RPMS Mode 2050 RPML Mode 1950 RPM

H Mode mA = 600S Mode mA = 490L Mode mA = 280


35.0

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000


Flow

= (G

PM)




53.852.3

25.8

14.5

48.8 48

23.7

10

46.2 45.4

23

8.4

0

10

20

30

40

50

60

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000

Pressure = (PSI) P1 + P2

Flow

= (G

PM)




55

0

10

20

30

40

50

60

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000


Flow

= (G

PM)



CX240 Theoretical Pump Flow L, S, & H ModeTSG - Technical Service Group

56.80354.9536

30.1188

18.7582

51.7832 50.9906

28.0052

13.21

49.4054 48.877

26.9484

9.5112

0

10

20

30

40

50

60

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000


Flow

(GPM

)

H Mode 2180 RPMS Mode 2000 RPM L Mode 1900 RPM


CX240 Theoretical Pump Flow L, S, & H ModeTSG - Technical Service Group

55

0

10

20

30

40

50

60

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000


Flow

(GPM

)

H Mode 2180 RPMS Mode 2000 RPM L Mode 1900 RPM



56.2746

32.2324

20.8718

52.0474

30.1188

15.0594

49.9338

29.062

11.3606

58.124

53.368450.9906

0

10

20

30

40

50

60

70

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000


Flow

= (G

PM)




60

0

10

20

30

40

50

60

70

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000


Flow

= (G

PM)



Construction Equipment Service Training

Section 3 --Controller

CX SERIESEXCAVATOR

(2004)

CNH America LLC 2004700 STATE STREET All Rights ReservedRACINE, WI 53404 U.S.A. Printed in U.S.A..

CONTROLLER

3- 1 CX EXCAVATORS

Table of Contents

Section 3 - CX Series Controller

CONTROLLER CALIBRATION.................................................................... 3

CHANGE THE DISPLAY LANGUAGE ONLY............................................ 11

CURRENT CONDITION DISPLAY ............................................................ 17

DIAGNOSTIC CONDITION DISPLAY ....................................................... 32

EXCAVATOR HISTORY DISPLAY............................................................ 38

OPTIONAL RESET DISPLAY.................................................................... 51

CONTROLLER

3- 2 CX EXCAVATORS

CONTROLLER CALIBRATION and DIAGNOSTICSYSTEMSWITCHES

Work Mode Switch

Travel Mode Switch Auto Mode SwitchBuzzer Stop Switch

Cushion Switch

CONTROLLER

3- 3 CX EXCAVATORS

CONTROLLER CALIBRATION PROCEDURE

CONTROLLER RESET

Machine confirmation

In the normal display mode, when the Auto mode switch is pressed for 10seconds, the machine selection screen will be displayed.

Confirmation of the machine model, territory, language and computer part number can be done at this screen.

If you do not need to make any changes, press the Auto mode switch againand the Display will return to the normal mode.

If you only need to change the language, go to page 3-11.

If you need to make changes, procede to the next page.

MACHINE: SH0200 –3TERRITORY: 2 LANGUAGE: 1

CONT. P/N KHR 3311

CONTROLLER

3- 4 CX EXCAVATORS


CONTROLLER RESET

Note: For CX130 & CX160 Excavators only, Warm up the Excavatorbefore clearing the machine selection screen. Return to the normalmode screen by pressing and releasing the Auto Mode switch. Then pressthe Travel Mode and Work Mode Switches together longer than 3 secondsto go to the CHK1 screen (see page 3-15). Make sure that the coolanttemperture (WT) is at least 160°F (70°C) and that the ENG section isindicating the engine speed. To warm up the engine, watch the CHK1Screen while holding the arm-in function at Wide-Open-Throttle. When thetemperature (WT) reaches 160°F, turn off the Engine.Turn the Key Switch on and press the Auto mode switch for 10 seconds toReturn to the Controller Reset Screen.

All Excavators: Press the Auto mode switch for 10 seconds to clear alldata in this screen. All data will change to “?” and the buzzer will sound.

Turn off the key switch to finish clearing the data.

MACHINE: SH ? –3TERRITORY: ? LANGUAGE: ?

CONT. P/N KHR XXXX

CONTROLLER

3- 5 CX EXCAVATORS


1. Turn the key switch “ON”

A “?” is shown at MACHINE, TERRITORY and LANGUAGE areas.

A “?” shown with dark background means that item is selected andready to be changed.

A “−3” means CX series

2. The machine model code will change in the dark background area everytime the Travel mode switch is pressed.

Select the correct model code that corresponds with the machine.

MACHINE: SH ? –3TERRITORY: ? LANGUAGE: ?

CONT. P/N KHR XXXX

MACHINE: SH0200 –3TERRITORY: ? LANGUAGE: ?

CONT. P/N KHR XXXX

Machine Code Case NASH0120 CX130SH0150 CX160SH0200 CX210SH0220 CX240SH0250 CX290SH0300 CX330SH0400 CX450SH0800 CX800

CONTROLLER

3 - 6 CX EXCAVATORS


3. After selecting the model, it is necessary to select the correctpump code on some excavator models. Press the Buzzer Stopswitch to select the correct Pump by changing the last digit in themodel code from 0 to 1 or 2, see chart below.

SH0120 (UCHIDA PUMP)SH0121 (KAWASAKI PUMP)– DAC0713246 & After

CX130

SH0150 (UCHIDA PUMP)SH0151 (KAWASAKI PUMP)– DAC0716270 & After

CX160

SH0200 (KAWASAKI PUMP)SH0202 (LIFTING MAGNET M/C) CX210SH0220 (KAWASAKI PUMP)SH0222 (LIFTING MAGNET M/C) CX240SH0250 (KAWASAKI PUMP) CX290SH0300 (UCHIDA PUMP)SH0301 (KAWASAKI PUMP)SH0302 (LIFTING MAGNET M/C)

CX330

SH0400 (KAWASAKI PUMP) CX460SH0800 (KAWASAKI PUMP) CX800

The CX130 PIN Break for the change to the Kawasaki Pump isDAC0713246, code SH0121.

The CX160 PIN Break for the change to the Kawasaki Pump isDAC0716270, code SH0151.

All North American CX330 excavators have the Kawasaki Pump, thereforethe code must be changed to SH0301.

CONTROLLER

3 - 7 CX EXCAVATORS


4. After selecting the model code, press the Work mode switch to selectthe Territory field.

A “?” shown with a dark background means that item is selected.

5. The Territory will change everytime the Travel mode switch is pressed.

Press the Travel mode switch until the number 2 appears in the Territoryfield for Case North America, pressure in psi and temperature in °F.

Other choices are: 0 for pressure in K(kg/cm² and temperture in °C.1 for LBX North America3 for pressure in MPa and temperature in °C.

To switch between European and US units, press the Working Light Key

MACHINE: SH0200 –3TERRITORY: ? LANGUAGE: ?

CONT. P/N KHR XXXX

MACHINE: SH0200 –3TERRITORY: 2 LANGUAGE: ?

CONT. P/N KHR XXXX

CONTROLLER

3 - 8 CX EXCAVATORS


6. Press the Work mode switch to select the language field.

A “?” shown with dark background means that item is selected.

7. Press the Travel mode switch to change the language. See languageselection chart below.

MACHINE: SH0200 –3TERRITORY: 2 LANGUAGE: ?

CONT. P/N KHR XXXX

LanguageCode

Language LanguageCode

Language

0 Japanese 8 Portuguese

1 English 9 Dutch

2 Thai 10 Danish

3 Chinese 11 Norwegian

4 German 12 Swedish

5 French 13 Finnish

6 Italian 14 Icons

7 Spanish 15

CONTROLLER

3 - 9 CX EXCAVATORS


Continue with step 8 for CX130 / CX160 ONLY

(Go to the next page for CX210 / CX800 Continue with step 10)

8. After inputting all machine information, start the engine, turn the throttleto 50% and push the Cushion switch. The engine will go to full RPM andthen slowly lower to idle. If the Auto Idle was turned off, the engine willthen speed up to 50% to confirm that it is finished.

Note: Coolant temperature must be above 122°F (50°C) before theprocedure will start. Cover the radiator if necessary to warm the engine.

The process is finished when the engine RPM can be controlled by thethrottle control again.

9. Press the Auto mode switch to finish, and return to the normal display.


CONT. P/N KHR XXXX

CONTROLLER


10. After inputtiThe CASE logdisplay below.


CX210 / CX800

ng all machine information, push the Auto mode switch.o will be displayed, then automatically scroll to the normal

CONTROLLER



To change the language only, display the machine selection screen bypressing the Auto mode switch for 10 seconds.

The language is changed by pressing the Travel mode switch.

Press the Work mode switch to set the language, the buzzer will sound atthis time. Turn the key switch off to complete the process.


CONT. P/N KHR XXXX

CONTROLLER


DIAGNOSTIC MODE FLOW CHART

1 = (T + W) > 3 Seconds 5 = T > 10 Seconds, CHK6 displays2 = Auto beeping occurs.3 = Alarm Stop (Buzzer Stop) 6 = To erase see Page 3-14 description.4 = T > 1 < 10 Seconds (Push and hold to read CHK5)To record faults, with the Key off, Hold down the One-Touch Idle & turn theKey on, release the Idle key and the computer will self check.

RESETTINGRST1

NORMALDISPLAYMODE

DIAGNOSTICMODE

DIAGNOSTICSYSTEMDIAG1

EXCAVATOR

HISTORY

12 2 2CURRENT

CONDITIONCHK1

CHK2

CHK3

CHK4

CHK5

CHK6

3

3

3

3DIAG2

DIAG3

DIAG4

DIAG5

DIAG6

3

3

3

3

3

3

HR2HR12

HR3HR11

HR4HR10

HR5

HR6

HR7

HR9

HR8

3 3

33

33

3 3

3

3

3

3

BRK

L/M

AI

PA

AU

HLD

OUT

3

3

3

3

3

3

3

3

4

5

6

6

6

6

CONTROLLER


DIAGNOSTIC MODECurrent Condition (CHK1-CHK6)

Displays the excavator’s current condition.Diagnostic System (DIAG1-DIAG6)

Displays recorded fault codes of current and past conditions for the engineand the excavator. Records the computer hours of the detection of thefault.

Excavator History (HR1-HR12)Displays recorded computer hours of each excavator operation.

Resetting (RST1-RST2) Displays the excavator’s current settings and allows for the changing of theexcavator setup.

EXPLAINATION OF DIOGNOSTIC STEPS1 To scroll between the Normal display and Diagnostic display screenspress the Travel and Work mode switch simultaneously for 3 seconds.2 To scroll across between the CHK, DIAG, HR and RST screens, pressthe Auto mode switch.3 To scroll down through the CHK, DIAG, HR and RST screens, press theBuzzer stop switch. 4 A Self-Check of the protected transistor circuits can be checkedautomatically. While holding the One-Touch idle button down, turn the keyswitch on, then release the idle button. The controller will energize each ofthe transistor (TR) circuits automatically. If a short-circuit is detected, thedisplay will indicate an “ELECTRICAL PROBLEM” and sound the buzzer.If no over-current is detected, the travel alarm will sound.

To find the shorted circuit, go immediately to the CHK1 screen withoutturning off the Key Switch, then scroll to the CHK2 screen. While in theCHK2 screen, press and hold the Travel mode switch, you will scroll to theCHK5 screen. Recorded TR1, TR2 and TR3 faults will be displayed.

5 If you hold the Travel switch down longer than 10 seconds the CHK6screen appears and the buzzer beeps intermittently. The same faults aredisplayed in the CHK6 screen. Turning off the Key switch erases the codesand silences the buzzer.

CONTROLLER


6 To erase data in DIAG2, DIAG5, or HR1-HR12 screens, scroll to DIAG2,DIAG5 or HR1. At each of these fields, press the Work mode switch for 10seconds, (the buzzer will sound), turn OFF the key switch. Erasing the datain the HR1 screen removes the history from all of the History screens, HR1through HR12.

CONTROLLER


CURRENT CONDITION CHK1

• Mode: To reach this screen, Press and hold both the Travel and Workmode switches more than 3 seconds.

• P1: Main Pump Pressure (P1)• P2: Main Pump Pressure (P2)• N: Negative Control Pressure of pump supplying Arm 1 Spool.• ENG: Engine RPM• I: Current for Pump Proportional Solenoid• WT: Water Temperature• OT: Hydraulic Oil Temperature

Use this screen to check main relief and power boost settings. Verifynegative control pressure from the arm/swing pump, engine RPM,controller signal to the proportional solenoid on the pump and hydraulic oiland coolant temperature.

Use the Buzzer stop switch to scroll through CHK1 – CHK4 screens.

Use the Travel switch to scroll to the CHK5 screen from the CHK2 screen.

CHK MODE 2 H

1 ENG 0 0 0 0 RPM

P1 0 0 0 0 PSI I 0 0 0 0 mA

P2 0 0 0 0 PSI WT 0 0 0 0 F

N 0 0 0 0 PSI OT 0 0 0 0 F

CONTROLLER

3


• R: Engine Load Ratio (CX210/CX240)• FT: Fuel Temperature (CX210/CX240)• TV: Throttle Volume• TR1: Transistor Output• TR2: Transistor Output• TR3: Transistor Output• TR4: Not Used

R: CX210/CX240 Information sent from thmain controller uses this information for rethis information plus pump pressure to de

FT: CX210/CX240 Information sent from tThe main controller uses this information

TV: Use this field to verify that the controlcontrol knob.

TR1, TR2, TR3: These fields can be usedsignal to turn these various circuits on and

CHK MODE 2 H

2 TR1 0 0 0 0

R 0 0 0 0 % TR2 0 0 0 0

FT 0 0 0 0 F TR3 0 0 0 0

TV 0 0 0 0 % TR4 0 0 0 0

Engine Load Ratio

((Q-Qn) / (Qf-Qn))

Fuel Flow:

Q – Current

Qn – No Load

Qf – Maximum Flow

- 16 CX EXCAVATORS

e engine controller to the main controller. Thecording purposes. The controller also usestermine when to activate Auto Power Boost.

he engine controller to the main controller.for recording monitoring purposes.

ler is receiving the signal from the throttle

to verify that the controller is sending the off as they are selected by the operator.

CONTROLLER


CURRENT CONDITION CHK2Continued

This screen can be used to verify that the controller is sending a signal tothe circuits listed.

TRANSISTOR OUTPUT (0=OFF, 1=ON)

Start the engine and engage lever lock (pilot pressure).

• Swing Park Brake - Move the swing hand control just enough to close the swingpressure switch. Should see the 1 change to 0. Return the hand control to neutral.The 0 should change to 1 after 5 seconds. Slowly raise the boom until screenindicates swing brake is turned off. Return boom control to neutral. Swing brakeshould be turned on 5 seconds later.

• High Speed Travel & Travel Alarm – Press the travel switch to select high-speedtravel. The high speed travel field should change to a 1 and to 0 when the switch ispressed again. Move a travel foot control just enough to close the travel pressureswitch. Should see the alarm field change to a 1 and change back to 0 when the footcontrol is released.

• Power Boost – CX210/CX240 -Move one of the attachments to end of stroke. Asthe pressure increases the power boost field should change to a 1 as the AutoPower Boost is engaged. Power boost should be on for 8 seconds. Select L modewith the Work mode switch. Power boost should be turned on until another workmode is selected.

• Power Boost – CX130/CX160 – Press the one-touch switch on the front of the righthand control. The power boost field should change to a 1 for 8 seconds. Select Lmode with the Work mode switch. Power boost should be turned on until anotherwork mode is selected.

TR1 0 0 0 0

• Swing Park Brake

• High Speed Travel

• Travel Alarm

• Power Boost

CONTROLLER




• Battery Relay – There should be a 1 here anytime the key switch isturned on. Can not observe off signal.

• Cushion Valve (off/on) – While the engine is running, push the cushionswitch, A 1 should appear in the cushion valve field. When the cushionswitch is pressed again, the 1 should be changed to a 0.

• Swing shut off – With the key switch on, push the swing lock switch,the swing shut off field should change to a 1. When the swing lock ispushed again the field should change to a 0.

• Swing Priority – This feature is not used. The Swing Priority valve inthe main control is shifted by hydraulic Pilot Pressure from the shuttlevalve.

TR2 0 0 0 0

• Battery Relay

• Cushion Valve (off/on)

• Swing Shut Off

• Swing Priority

CONTROLLER




• Free Swing – With the engine running press the free swing switch thefree swing field should change to a 1. When the switch is pressed againthe 1 should be changed back to 0.

TR3 0 0 0 0

• Free Swing

• Thief Proof

• Not Used

• Not Used

TR4 0 0 0 0

• Not Used

• Not Used

• Not Used

• Not Used

CONTROLLER



This screen is used to verify that the controller is receiving the input fromthe listed switches and signals.

• SW1: Upper pressure switch, travel pressure switch, swing pressureswitch and hammer pressure switch.

• SW2: Engine oil pressure switch, coolant level switch, and auxiliarypressure switch.

• SW3: Battery charge.

• SW4: Cushion switch (off/on), free swing switch, swing priority switch(Not used) and one touch idle switch.

• SW5: Swing lock switch, emergency stop switch, work light and wiperswitch.

• SW6: Windshield washer switch, travel alarm and hammer mode switch,and Material Handling (L/M) mode.

• SW7: Thief Proof, Key switch, and Overload (EU).

CHK MODE 2 H 3 SW4 0 0 0 0

SW1 0 0 0 0 SW5 0 0 0 0

SW2 0 0 0 0 SW6 0 0 0 0

SW3 0 0 0 0 SW7 0 0 0 0

CONTROLLER



Continued

SWITCH INPUT (0=OFF, 1=ON)

Start the engine and engage the lever lock (pilot pressure).

• Engage any upper function for the upper pressure switch.

• Engage the swing for the swing and upper pressure switch.

• Engage the travel function for the travel pressure switch.

• Engage the hammer circuit, if equipped, for the hammer pressureswitch.

NOTE: The pressure switches should come on before the hydraulic circuitis active.

SW1 0 0 0 0

• Upper pressure switch

• Travel pressure switch

• Swing pressure switch

• Hammer pressure switch

CONTROLLER



Continued


• Engine oil pressure switch is “ON” with low pressure or when engine isoff. CX130/CX160 ONLY.

• Coolant level switch is “ON” when coolant level is low

• Observe with engine running. Should be “ON”.

SW2 0 0 0 0

• Engine oil pressure switch

• Coolant level switch

• Auxiliary Pressure Switch

• Not used

SW3 0 0 0 0

• Alternator signal

• Not used

• Not used

• Not used

CONTROLLER



Continued


Key Switch “ON”

• These are momentary switches. They are “ON” only while they are beingpressed.

• These are momentary switches. They are “ON” only while they are beingpressed.

SW4 0 0 0 0

• Cushion switch (off/on)

• Free Swing switch

• Swing Priority-Not used

• One touch idle switch

SW5 0 0 0 0

• Swing lock switch

• Emergency Stop switch

• Work light switch

• Wiper switch

CONTROLLER



Continued


Key Switch “ON”

• Washer switch is a momentary switch. It is “ON” only while the switch isbeing pressed.

• The travel alarm switch is a 2-position rocker switch on the left consoleand has a “0” in the third position when “OFF”, and a “1” when in thecontinuous position.

• The auxiliary hydraulic mode switch is a 3-position rocker switch, thereis a “1” when in the hammer position

• The Material Handling is presently not used.

SW6 0 0 0 0

• Windshield washer switch

• Travel alarm off/on switch

• Hammer. Mode switch

• Material Handling (L/M)

CONTROLLER



Continued


Key Switch “ON”

• “ON” when the key switch is.

SW7 0 0 0 0

• Thief Proof

• Key switch

• Not used

• Not used

CONTROLLER



• FS: Fuel Sensor Resistance• AC: Coolant Temperature for A/C Control• TR5: Not Used• TG: Target Engine RPM• BP: Not Used• SP1: Not Used• SP2: Not Used

CHK MODE 2 H 4 TG 0 0 0 0 RPM

FS 0 0 0 0 OHMS BP 0 0 0 0 MPa

AC 0 0 0 0 SP1 0 0 0 0

TR5 0 0 0 0 SP2 0 0 0 0

CONTROLLER



Continued

Press the Buzzer stop switch to return to CHK1.

AC 0 0 0 0

• 1: Water temperature: <86°F

• 2: Water temperature is between: 86°F & 113°F



CONTROLLER


PRESENT OVER LOAD CONDITION CHK5

• R: Engine Load Ratio (CX210/CX240)• FT: Fuel Temperature (CX210/CX240)• TV: Throttle Volume• TR1: Transistor output has detected an over current• TR2: Transistor output has detected an over current• TR3: Transistor output has detected an over current• TR4: Not Used

A Self-Check of the protected transistor circuits can be done automatically.While holding the One-Touch idle button down, turn the key switch on, thenrelease the idle button. The controller will energize each of the transistor(TR) circuits automatically. If a shorted-circuit is detected, the display willindicate an “ELECTRICAL PROBLEM” and sound the buzzer. If no over-current is detected, the travel alarm will sound.If a short is indicated, do not turn off the key switch. Press the Travel andWork mode buttons together to go to the CHK1 screen. Press the buzzerstop switch to scroll to the CHK2 screen. While in the CHK2 screen, pressand hold the Travel mode switch, this will allow you to view the CHK5screen. The CHK5 screen displays a “1” in the “TR” section if an overcurrent was detected. If you hold the switch down longer than 10 secondsthe buzzer will sound and the CHK6 screen will be displayed. The key mustbe turned off to silence the buzzer, which also erases the fault codes.

Note: To erase the fault codes in the CHK5 screen, just switch the keyswitch off.

CHK MODE 2 H 5 TR1 0 0 0 0

R 0 0 0 0 % TR2 0 0 0 0

FT 0 0 0 0 F TR3 0 0 0 0

TV 0 0 0 0 % TR4 0 0 0 0

CONTROLLER


PAST OVER LOAD CONDITION CHK5

Continued

TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload)

TR1 0 0 0 0

• Swing Park Brake

• High Speed Travel

• Travel Alarm

• Power Boost

TR2 0 0 0 0

• Battery Relay

• Cushion Valve

• Swing Shut Off

• Swing Priority

CONTROLLER


PAST OVER LOAD CONDITION CHK5

Continued

TRANSISTOR OUTPUT (0 = No Overload, 1 = Overload)

TR3 0 0 0 0

• Free Swing

• Thief Proof

• Not Used

• Not Used

TR4 0 0 0 0

• Not Used

• Not Used

• Not Used

• Not Used

CONTROLLER


SELF - CHECK CHK6

• R: Engine Load Ratio (CX210/CX240)• FT: Fuel Temperature (CX210/CX240)• TV: Throttle Volume• TR1: Transistor output has detected an over current• TR2: Transistor output has detected an over current• TR3: Transistor output has detected an over current• TR4: Not Used

NOTE: While viewing the CHK5 screen, if the Travel mode switch is heldlonger than 10 seconds, the CHK6 screen will appear. The buzzer willsound until the key switch is turned off, the fault codes will be erased.

Transistor output can be checked for over current (short to ground)automatically. To do this hold down the one-touch idle switch while you turnon the key, then release the one-touch switch. You will hear the systemcheck itself. If there is no short circuit detected, the travel alarm will sound.If a short circuit is detected, the buzzer will sound intermittently and“ELECTRICAL PROBLEM” will be displayed on the screen. The CHK5screen will indicate which circuit the fault is in. See pages 3-29 and 3-30 foridentification of the fault location.

CHK MODE 2 H 6 TR1 0 0 0 0

R 0 0 0 0 % TR2 0 0 0 0

FT 0 0 0 0 F TR3 0 0 0 0

TV 0 0 0 0 % TR4 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEM CX210/CX240DIAG1 – Current Engine Failure Condition

E 0000 No FailuresE 0111 ECM internal Hardware ErrorE 0115 No engine speed detected at enginespeed sensor.E 0122 High voltage detected at Boostpressure sensor.E 0123 Low voltage detected at Boostpressure sensor.E 0131 Throttle position sensorE 0132 Throttle position sensorE 0135 Oil pressure highE 0141 Oil pressure sensor lowE 0143 Oil pressure sensor / EPFE 0144 Coolant temp sensor highE 0145 Coolant temp sensor lowE 0146 Coolant temp sensor / EPFE 0151 Coolant temp sensor / EPFE 0153 Intake air temp sensor highE 0154 Intake air temp sensor lowE 0155 Intake air temp sensor / EPFE 0234 ESS, crankshaft position sensorE 0235 Coolant level sensor / EPFE 0261 Fuel temp sensor pump over-heatE 0264 VP44 fuel temp sensorE 0278 Lift pump relayE 0283 ESS/Crankshaft position sensor highE 0284 ESS/Crankshaft position sensor lowE 0319 EECME 0352 Sensor voltage supplyE 0361 VP44 fuel system high currentE 0362 VP44 fuel system value openE 0363 VP44 fuel system feed back errorE 0364 VP44 fuel system com error

E 0365 VP44 fuel system lowE 0366 VP44 fuel system measurement errorE 0367 VP44 fuel system IAT errorE 0368 VP44 fuel system timing errorE 0369 VP44 fuel system sync errorE 0372 VP44 fuel system idle validation errorE 0373 VP44 fuel system FSO highE 0374 VP44 fuel system shutoff errorE 0376 VP44 fuel system mismatch errorE 0377 Fuel pump power shutoff relayE 0381 Intake air heater control error, relay 2E 0386 Engine sensor voltage supply highE 0391 Fuel pump power shutoff relayE 0415 Oil pressure sensor / EPFE 0418 Water in fuel sensorE 0422 Coolant level sensorE 0429 Water in fuel sensorE 0431 Throttle position sensor lowE 0433 Boost pressure highE 0434 ECME 0441 Battery voltage lowE 0442 Battery voltage highE 0443 Throttle position sensorE 0488 Intake air temp sensor / EPFE 0517 Fuel pump has a stuck control valveE 0524 High speed governor droop switchE 0611 Hot shutdown error

Note: Go to Section 8, Page 19~24 for thefault description in more detail.

DIAG MODE 2 H 1 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEM CX210/CX240DIAG2 – Past Engine Failure Condition

E 0000 No FailuresE 0111 ECM internal Hardware ErrorE 0115 No engine speed detected at enginespeed sensor.E 0122 High voltage detected at Boostpressure sensor.E 0123 Low voltage detected at Boostpressure sensor.E 0131 Throttle position sensorE 0132 Throttle position sensorE 0135 Oil pressure highE 0141 Oil pressure sensor lowE 0143 Oil pressure sensor / EPFE 0144 Coolant temp sensor highE 0145 Coolant temp sensor lowE 0146 Coolant temp sensor / EPFE 0151 Coolant temp sensor / EPFE 0153 Intake air temp sensor highE 0154 Intake air temp sensor lowE 0155 Intake air temp sensor / EPFE 0234 ESS, crankshaft position sensorE 0235 Coolant level sensor / EPFE 0261 Fuel temp sensor pump over-heatE 0264 VP44 fuel temp sensorE 0278 Lift pump relayE 0283 ESS/Crankshaft position sensor highE 0284 ESS/Crankshaft position sensor lowE 0319 EECME 0352 Sensor voltage supplyE 0361 VP44 fuel system high currentE 0362 VP44 fuel system value openE 0363 VP44 fuel system feed back errorE 0364 VP44 fuel system com error

E 0365 VP44 fuel system lowE 0366 VP44 fuel system measurement errorE 0367 VP44 fuel system IAT errorE 0368 VP44 fuel system timing errorE 0369 VP44 fuel system sync errorE 0372 VP44 fuel system idle validation errorE 0373 VP44 fuel system FSO highE 0374 VP44 fuel system shutoff errorE 0376 VP44 fuel system mismatch errorE 0377 Fuel pump power shutoff relayE 0381 Intake air heater control error, relay 2E 0386 Engine sensor voltage supply highE 0391 Fuel pump power shutoff relayE 0415 Oil pressure sensor / EPFE 0418 Water in fuel sensorE 0422 Coolant level sensorE 0429 Water in fuel sensorE 0431 Throttle position sensor lowE 0433 Boost pressure highE 0434 ECME 0441 Battery voltage lowE 0442 Battery voltage highE 0443 Throttle position sensorE 0488 Intake air temp sensor / EPFE 0517 Fuel pump has a stuck control valveE 0524 High speed governor droop switchE 0611 Hot shutdown error

Note: Go to Section 8, Page 19~24 for thefault description in more detail.

DIAG MODE 2 H 2 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEM CX210/CX240DIAG3 – Past Engine Failure Condition (Hour)

• The hours that fault occurred will be displayed in the same window asthe fault code that was detected in DIAG2.

• Past fault codes and hours will be cleared if the Work mode switch ispressed for 10 seconds.

• Hours shown in DIAG3 is computer “ON” hours since the last time thedata was cleared. Not excavator hour-meter hours.

Note: To erase engine fault codes switch to DIAG2 and press the Workmode switch for 10 seconds. The warning buzzer will sound. Turn OFF thekey switch to complete the process.

DIAG MODE Hi, H 3 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

E 0 0 0 0 E 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEMDIAG4 – Current Machine Failure Condition

M 0000: No Failure

M 0010: Transistor output short circuit, (see page 3-28)

M 0020 Hydraulic oil temperature sensor

M 0030 Fuel sensor

M 0040 Pressure sensor (P1)


M 0060 Pressure sensor (N2, negative control)

M 0070 Key switch

M 0080 Pressure switch (upper or travel)

M 0090 CAN communication error (CX210/CX240)

M 00A0 Computer reset

M 00D0 Throttle motor related problem (CX130/CX160)

M 00E0 Coolant level sensor (CX130/CX160)

M 00F0 RPM sensor (CX130/CX160)

DIAG MODE Hi, H 4 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEMDIAG5 – Past Machine Failure Condition

M 0000: No Failure

M 0010: Transistor output short circuit

M 0020 Hydraulic oil temperature sensor

M 0030 Fuel sensor



M 0060 Pressure sensor (N2, negative control)

M 0070 Key switch

M 0080 Pressure switch (upper or travel)

M 0090 CAN communication error (CX210/CX240)

M 00A0 Computer reset

M 00D0 Throttle motor related problem (CX130/CX160)

M 00E0 Coolant level sensor (CX130/CX160)

M 00F0 RPM sensor (CX130/CX160)


M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

CONTROLLER


DIAGNOSTIC SYSTEMDIAG6 – Past Machine Failure Condition (Hours)

• The hours that fault occurred will be displayed in the same window asthe fault code that was detected in DIAG5.

• Past fault codes and hours will be cleared if the Work mode switch ispressed for 10 seconds.

• Hours shown in DIAG6 is computer “ON” hours since the last time thedata was cleared. Not excavator hour-meter hours.

Note: To erase machine fault codes switch to DIAG5 and press the Workmode switch for 10 seconds. The warning buzzer will sound. Turn OFF thekey switch to complete the process.


M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

M 0 0 0 0 M 0 0 0 0

CONTROLLER


EXCAVATOR HISTORY

HR1

ENG: Hour Meter, hours (engine running) since last cleared

WRK: Operating hours (pressure switch “ON”)

U: Upper operating hours

T: Travel operating hours

S: Swing operating hours

PU: Power Boost operating hours

BRK: Hammer operating hour

Use the Buzzer stop switch to scroll through the HR screens.

Note: To erase the work history data from all of the HR screens, scroll tothe HR1 screen, press and hold the Work mode switch for 10 seconds(buzzer will sound). Turn OFF key.

HR MODE Hi, H 1 T 0 0 0 0 HR

ENG 0 0 0 0 HR S 0 0 0 0 HR

WRK 0 0 0 0 HR PU 0 0 0 0 HR

U 0 0 0 0 HR BRK 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORY

HR2

H: H work mode operating hours

S: S work mode operating hours

L: L work mode operating hours

A: Auto work mode operating hours

WT: Maximum coolant temperature recorded since the lasttime the data was cleared

OT: Maximum hydraulic oil temperature recorded since thelast time the data was cleared

FT: Maximum fuel temperature recorded since the last timethe data was cleared (CX210/CX240)

HR MODE Hi, H 2 A 0 0 0 0 HR

H 0 0 0 0 HR WT 0 0 0 0 F

S 0 0 0 0 HR OT 0 0 0 0 F

L 0 0 0 0 HR FT 0 0 0 0 F

CONTROLLER


EXCAVATOR HISTORY

HR3

1: Computer power “ON” hours

2: Low speed operating hours

3: High speed operating hours

4: Independent travel operating hours

5: Maintenance timer

HR MODE Hi, H 3 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 F

2 0 0 0 0 HR 6 0 0 0 0 F

3 0 0 0 0 HR 7 0 0 0 0 F

CONTROLLER


EXCAVATOR HISTORY

HR4

P1 Pressure Distribution (pump 1)

1: P1 operating hours, under 1450 PSI

2: P1 operating hours, 1450 to 2176 PSI





7: P1 operating hours, over 5076 PSI

HR MODE Hi, H 4 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORY

HR5

P2 Pressure Distribution (pump 2)

1: P2 operating hours, under 1450 PSI






7: P2 operating hours, over 5076 PSI

HR MODE Hi, H 5 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORY

HR6

Engine Speed (RPM) Distribution

1: Hours, under 1175 RPM

2: Hours, 1175 to 1375 RPM

3: Hours, 1375 to 1575 RPM

4: Hours, 1575 to 1775 RPM

5: Hours, 1775 to 1975 RPM

6: Hours, 1975 to 2175 RPM

7: Hours, over 2175 RPM

HR MODE Hi, H 6 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORY

HR7

Coolant Temperature Distribution

1: Hours, under 171°F (1st and 2nd Bars)

2: Hours, 171°F to 180°F (3rd Bar)

3: Hours, 180°F to 207°F (4th Bar)




7: Hours, over 221°F

HR MODE Hi, H 7 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORY

HR8

Hydraulic Oil Temperature Distribution

1: Hours, under 113°F (1st and 2nd Bars)

2: Hours, 113°F to 140°F (3rd Bar)






HR MODE Hi, H 8 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


EXCAVATOR HISTORYCX210/CX240

HR9

Fuel Temperature Distribution

1: Hours, under 86°F

2: Hours, 86°F to 104°F

3: Hours, 104°F to 122°F

4: Hours, 122°F to 140°F

5: Hours, 140°F to 158°F

6: Hours, 158°F to 176°F


HR MODE Hi, H 9 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER



HR10

Load Ratio Distribution

1: Hours, under 30%

2: Hours, 30% to 40%

3: Hours, 40% to 50%

4: Hours, 50% to 60%

5: Hours, 60% to 70%

6: Hours, 70% to 80%

7: Hours, over 80%

HR MODE Hi, H 10 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER



HR11

Load Ratio Distribution in H Mode, High Idle

1: Hours, under 30%

2: Hours, 30% to 40%

3: Hours, 40% to 50%

4: Hours, 50% to 60%

5: Hours, 60% to 70%

6: Hours, 70% to 80%

7: Hours, over 80%

HR MODE Hi, H 11 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER



HR12

Load Ratio Distribution in S Mode, High Idle

1: Hours, under 30%

2: Hours, 30% to 40%

3: Hours, 40% to 50%

4: Hours, 50% to 60%

5: Hours, 60% to 70%

6: Hours, 70% to 80%

7: Hours, over 80%

HR MODE Hi, H 12 4 0 0 0 0 HR

1 0 0 0 0 HR 5 0 0 0 0 HR

2 0 0 0 0 HR 6 0 0 0 0 HR

3 0 0 0 0 HR 7 0 0 0 0 HR

CONTROLLER


RESETTINGRST1

BRK: Programmed RPM for Hammer mode

L/M: Old computer Not Used, New Computer includesthis feature for Material Handling.

AI: Auto-Idle setting time, (1 to 30 seconds) factorysetting is 5 seconds

PA: Altitude compensation (0 = off, 1, 2 or 3 = on), Eachreduces the pump output by reducing the current tothe proportional valve by 100, 150 or 200 MA. Thisfeature can be used for a sick engine to cut backpump flow.

AU: Auto Power Boost Cancellation (0 = off, 1 = on)Not available on CX130 or CX160.Does not turn off Power Boost in L Mode.

HLD: Hold previous (default) data (0 = with, 1 = without)

OUT: Not Used

Use the Buzzer stop switch to scroll through Resetting.

RST MODE Hi,H 1 PA 0 0 0 0

BRK 0 0 0 0 RPM AU 0 0 0 0

L/M Not Used RPM HLD 0 0 0 0

AI 0 0 0 0 SEC OUT Not Used

CONTROLLER


RESETTINGEngine Speed for Hammer Mode

Push the Buzzer stop switch to select BRK (item selected will have a lightbackground).

CX130/CX160To set engine speed for hammer mode, start the engine and adjust RPMwith the throttle control. Monitor will show actual RPM. Press the Workmode switch for 10 seconds to select the displayed RPM. The buzzer willsound to notify that 10 seconds have elapsed. Turn the throttle to low idle.Turn the key switch off.

CX210/CX240Start the engine and adjust engine speed to desired RPM using the FreeSwing switch to increase RPM and the Cushion switch to decrease RPM.The switches must be held for 5 seconds for a RPM change to occur.Press and hold the work mode switch for 10 seconds. The alarm buzzer willsound. Press the buzzer switch twice to change the display to AI. Turn thethrottle to idle and turn off the key switch.

To confirm, start the engine, turn up the RPM, access the CHK1 screenand observe the RPM when the hammer circuit is activated.

RST MODE Hi, H 1 PA 0 0 0 0

BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTING

L/M: Not used

OUT: Not used


BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTINGAuto Idle Time Set

Push the Buzzer stop switch to select AI (item selected will have a lightbackground).

To set the Auto-Idle time from 0 through 30 seconds, press the Travelmode switch until the number changes to your selection. The numberincreases by 1 every time the switch is pushed.

To save this data press and hold the Work mode switch for 10 seconds.The buzzer will sound to notify when 10 seconds have elapsed.

Turn the key switch off to complete the procedure.


BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTINGAltitude Compensation (pump power set)

Push the Buzzer stop switch to select PA (item selected will have a lightbackground)

PA: 0 = Normal Mode

PA: 1, 2 or 3 = Low Power Mode settings, reduces the pump output bydecreasing the maximum current to the proportional valve by 100, 150 or200. MA The engine stays the same speed.

To set the lower pump power mode (altitude compensation), push theTravel mode switch to change the 0 to 1, 2 or 3 for a lower power mode or0 for normal power mode.

To save the data, press the Work mode switch for 10 seconds. The buzzerwill sound to notify when 10 seconds have elapsed.



BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTINGAuto Power Boost Set (CX210/CX240)

Push the Buzzer stop switch to select AU (item selected will have a lightbackground)

AU: 0 = With Automatic Power Boost

AU: 1 = Without Automatic Power Boost (No Automatic Power Boost inthe H & S modes, Power Boost will still be on in the L Mode).

To set press the Travel mode switch to select 1 or 0.

To save the data push the Work mode switch for 10 seconds. The buzzerwill sound to indicate that 10 seconds have elapsed.


Note: This will not eliminate L mode full time power boost.


BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTINGPrevious Data Holding

Push the Buzzer stop switch to select HLD (item selected will have a lightbackground).

0 = Will hold default data1 = Will turn off default data, will return to setting when key is turned off

To set previous data holding feature, push the Travel mode switch until thenumbers change to the predetermined value in each column.

To set this data, press the Work mode switch for 10 seconds. The buzzerwill sound to indicate when 10 seconds have elapsed.



BRK 0 0 0 0 RPM AU 0 0 0 0



CONTROLLER


RESETTINGPrevious Data Holding

0 = Will hold default data1 = Will return to setting when key was turned off.Auto Mode0 = Auto Mode is the default mode whenever the key switch is turned on.1 = Whatever Mode was on when the key switch was turned off will be onthe next time the key is turned on.

Work Mode0 = Same as above1 = H Mode will be the default mode if Auto Mode is “1”.

Travel Mode0 = Low speed is the default whenever the key is turned on.1 = Whichever speed range was on when the key was turned off will be thespeed when the key is turned on.

Maintenance Timer Cancellation0 = Maintenance timer “ON”1 = Maintenance timer “OFF”

HLD 0 0 0 0

• Auto Mode

• Work Mode

• Travel Mode

• Maintenance Timer

CONTROLLER


Service Due WarningWhen the CX series was first introduced the service due maintenance timerwas set at a 500-hour interval and was unchangeable. Excavators equippedwith controller part number KHR2673 and after have adjustable timerintervals. The selected intervals are 50, 250, 500, 1000, 2000 or 5000 hours.

The controller part number for each excavator is determined by pushing andholding the auto mode switch for 10 seconds. The selection confirmationscreen for the excavator displays the controller part number. The timer intervalis adjustable if the controller part number is KHR2673 or higher. The displayreturns to the normal screen by pushing the auto mode switch.

CONTROLLER


Area 1 displays the remaining time before the SERVICE DUE warningdisplays in the monitor.

Area 2 displays the current (set) service due interval.

Areas 3 through 7 are not currently used.

With Area 2 highlighted, push the travel mode switch until the predeterminedvalue is displayed in the window. The timer interval selections are: 0500(default), 0050, 0250, 0500, 1000, and 2000. Stop when the desired interval isdisplayed.

Push and hold the work mode switch for 10 seconds to set the maintenancetimer service interval. The service interval is changed after the buzzer sounds.Turn the key switch off until the monitor window goes dark. Turn the key switchback on and the service interval is set.

SERVICE DUE WARNING CANCELLATION PROCEDURE

Hold the buzzer stop switch for 20 to 30 seconds while the service due warningis displayed to cancel the service due warning from displaying in the monitor.

NOTE: There are no audible warnings after the reset is completed. After 20 to30 seconds turn the key switch off.

NOTE: This procedure only resets the service due warning. This does notcancel the service due warning from displaying in the monitor at the nextpredetermined service interval time.

To completely turn off the SERVICE DUE warning feature, use theprocedure on the previous page (3-57, RST1 screen, the HLD area,Maintenance Timer Cancellation).

CX Series Diagnostic Screen Data SheetTechnical Service Group - 3/5/2003

CHECK DATE: CUSTOMER: DEALERSHIP:

MODEL: SERIAL NO.: HOUR METER:

1: STATUS INDICATION

CHK 1 ENG CHK 2 TR1 CHK 3 SW4P1 d I R TR2 SW1 SW5P2 d WT FT TR3 SW2 SW6N d OT TV TR4 SW3 SW7

CHK 4 TG CHK 2’ TR1 CHK 2” TR1FS BP R TR2 R TR2AC SP1 FT TR3 FT TR3TR5 SP2 TV TR4 TV TR4

2: DIAGNOSIS

DIAG 1 E DIAG 2 E DIAG 3 EE E E E E EE E E E E EE E E E E E

DIAG 4 M DIAG 5 M DIAG 6 MM M M M M MM M M M M MM M M M M M

3: MACHINE HISTORY

HR 1 T HR 2 A HR 3 4ENG S H WT 1 5WRK PU S OT 2 6

U BRK L FT 3 7

HR 4 4 HR 5 4 HR 6 41 5 1 5 1 52 6 2 6 2 63 7 3 7 3 7

HR 7 4 HR 8 4 HR 9 41 5 1 5 1 52 6 2 6 2 63 7 3 7 3 7

HR 10 4 HR 11 4 HR 12 41 5 1 5 1 52 6 2 6 2 63 7 3 7 3 7

CX Series Diagnostic Screen Data SheetTechnical Service Group - 3/5/2003

Field Information Key

1: STATUS INDICATIONCHK1 through CHK6 (CHK2' and CHK2'' included) display current conditions on the machine.Please use the service manual for detailed descriptions of these fields.

2: DIAGNOSISDIAG 1 DIAG 2 DIAG 3Current Engine Fault Codes Past Engine Fault Codes Hour - Past Engine Fault CodesDIAG 4 DIAG 5 DIAG 6Current Machine Fault Code Past Machine Fault Code Hour - Past Machine Fault Code

3: MACHINE HISTORYHR 1 HR 2 HR 3ENG engine hours since last cleared H H Mode operating hours 1 computer 'ON' hoursWRK operting hours (press. switch on) S S Mode operating hours 2 Low speed operating hours

U upper operating hours L L Mode operating hours 3 High speed operating hoursT travel operating hours A Auto Mode operating hours 4 Independent travel hoursS swing operating hours WT max water temp since last cleared 5 Maintenance timer

PU power boost operating hours OT max hyd temp since last cleared 6BRK hammer operating hours FT max fuel temp since last cleared 7

HR 4 P1 Pressure Distribution HR 5 P2 Pressure Distribution HR 6 RPM Distribution1 hours - under 1450 psi 1 hours - under 1450 psi 1 hours - under 1175 rpm2 hours - 1450 to 2176 psi 2 hours - 1450 to 2176 psi 2 hours - 1175 to 1375 rpm3 hours - 2176 to 2901 psi 3 hours - 2176 to 2901 psi 3 hours - 1375 to 1575 rpm4 hours - 2901 to 3626 psi 4 hours - 2901 to 3626 psi 4 hours - 1575 to 1775 rpm5 hours - 3626 to 4351 psi 5 hours - 3626 to 4351 psi 5 hours - 1775 to 1975 rpm6 hours - 4351 to 5076 psi 6 hours - 4351 to 5076 psi 6 hours - 1975 to 2175 rpm7 hours - over 5076 psi 7 hours - over 5076 psi 7 hours - over 2175 rpm

HR 7 Water Temp Distribution HR 8 Hyd Temp Distribution HR 9 Fuel Temp Distribution1 hours - under 171F (1 & 2 bar) 1 hours - under 113F (1 & 2 bar) 1 hours - under 86F2 hours - 171 to 180F (3rd bar) 2 hours - 113 to 140F (3rd bar) 2 hours - 86 to 104F3 hours - 180 to 207F (4th bar) 3 hours - 140 to 176F (4th bar) 3 hours - 104 to 122F4 hours - 207 to 212F (5th bar) 4 hours - 176 to 190F (5th bar) 4 hours - 122 to 140F5 hours - 212 to 217F (6th bar) 5 hours - 190 to 203F (6th bar) 5 hours - 140 to 158F6 hours - 217 to 221F (7th bar) 6 hours - 203 to 208F (7th bar) 6 hours - 158 to 176F7 hours - over 221F 7 hours - over 208F 7 hours - over 176F

HR10 Load Ratio (LR) Distribution HR11 LR - H Mode High idle HR12 LR - S Mode High idle1 hours - under 30% 1 hours - under 30% 1 hours - under 30%2 hours - 30% to 40% 2 hours - 30% to 40% 2 hours - 30% to 40%3 hours - 40% to 50% 3 hours - 40% to 50% 3 hours - 40% to 50%4 hours - 50% to 60% 4 hours - 50% to 60% 4 hours - 50% to 60%5 hours - 60% to 70% 5 hours - 60% to 70% 5 hours - 60% to 70%6 hours - 70% to 80% 6 hours - 70% to 80% 6 hours - 70% to 80%7 hours - over 80% 7 hours - over 80% 7 hours - over 80%

The service manual provides a more detailed description of these diagnostic screens.

ELECTRICAL

4 - 24CX EXCAVATORS

ELECTRIC/HYDRAULIC Pump Control, All Models1) In S, H and Auto modes supply current to Electro-magnetic proportional solenoid valve on

the side of the pump, will control the HP requirement of hydraulic pumps P1 and P2.

Note: The controller needs an RPM signal from the engine for the proportional solenoid valvepump control to function.H -MODE: For the pump flow to reach 100% capacity, a variable electrical signal is sent to

the proportional solenoid valve. The current varies with the engine speed.S -MODE: For the pump flow to reach 95% capacity, a variable electrical signal is sent to the

proportional solenoid valve. The current varies with the engine speed.L -MODE: For the pump flow to reach 70% capacity, no electrical signal is sent to the

proportional solenoid valve.AUTO -MODE: For the pump flow to work between 90% to 93% capacity of the engine target

torque, an electrical signal is sent to the proportional solenoid valve based on thecontroller selected mode. The controller switches the modes between the SA modeand the LA mode, depending on conditions. The maximum current will equal the Smode current + 40m A for the SA mode. The maximum current will equal the Smode for the LA mode.

When operating in the auto-mode and the SA mode is active, when the travel pressure switchis activated (closed), the excavator will stay in the SA mode until the travel switch opens. Ifthe excavator is in the LA mode when the travel pressure switch closes, the excavator willstay in the LA mode until the travel pressure switch opens.When operating in the L mode and the travel pressure switch closes, the excavator willoperate with the mA current of the S mode. If the hammer pressure switch closes, theexcavator will operate with the mA current of the S mode.The engine speed must exceed 1500 rpm before the controller sends current to the pumpproportional solenoid valve.

ELECTRICAL

4 - 25CX EXCAVATORS

ELECTRIC/HYDRAULIC

MODE H MODE AUTO MODEMODEL MAX MIN

S MODE L MODESA LA

CX130 600 mA 450 mA 450 mA 0 490 mA 450 mA

CX160 600 510 510 0 550 510

CX210 407 292 292 0 332 292

CX240 424 307 307 0 347 307

ELECTRICAL

4 - 26CX EXCAVATORS

ELECTRIC/HYDRAULICPower Boost, CX130/CX1601) Increases power when more force is required for digging operations. 2) By pushing the button on the front of the right joystick the main relief pressure is

increased for 8 seconds in the H and S modes.3) The Power Boost works at all times in the L mode.Note: The controller needs an RPM signal from the engine for the Power Boost to function.When the one-touch Power Boost switch is pressed “ON” (when working in the H or S mode),the signal enters in the main controller. 24v is sent to a solenoid valve from the controller andthe solenoid valve switches. The pilot pressure enters the main relief valve and the pressuresetting increases. “POWER UP” is displayed on the monitor. The increase in pressure isactivated for 8 seconds. The instrument panel will display “Power Up”, even if the PowerBoost switch is pressed for a long time, the pressure setting increases only for 8 seconds.The Power Boost can not be reactivated until the 8 second time frame has passed and theswitch is released and pressed again.In L mode Power Boost is active full time.When the travel or the hydraulic option pressure switch closes.(ON) the controller will turn offthe Power Boost solenoid.The Power Boost solenoid is in the six solenoid valve located in the pump compartment.

ELECTRICAL

4 - 27CX EXCAVATORS

POWER BOOSTCircuit Configuration

1. Power Boost switch2. Main Controller3. Power Boost solenoid valve4. Travel pilot pressure switch5. Main relief valve

Pressure increase in each work modeCX130/CX160

H MODES MODE 4970 → 5260 psi (8 seconds)

L MODE 4970 → 5260 (constant)AUTO MODE 4970 → 5260 (8 seconds)

ELECTRICAL

4 - 28CX EXCAVATORS

ELECTRIC/HYDRAULICAutomatic Power Boost, CX210/CX2401) In the H and the S work modes, the controller will automatically activate the Power Boost

solenoid valve to increase the main relief pressure.2) This increase is automatic without action by the operator.3) The increase will activate for only 8 seconds.4) The Power Boost is on full time in the L mode.Note: The controller needs an RPM signal from the engine controller for Power Boost tofunction.When operating in either the H or S mode, the main controller monitors the ratio between:- The load on the engine transmitted by the engine controller.- The load on the hydraulic system transmitted by the pressure transducers on pump P1

and pump P2.If the pressure of P1 or P2 is higher than 4351 psi (300 bar) and the load ratio remains withina range of ± 5% for 2 seconds, the controller sends a 24 volt signal to activate the PowerBoost solenoid for 8 seconds which increases the main pressure. The instrument panel willdisplay “Power Up”. To reactivate automatic Power Boost the load must be released andapplied again.When either the travel or the hydraulic option pressure switch is activated, the controllerdeactivates the Power Boost solenoid valve.The Power Boost solenoid valve is located in the six solenoid valve bank located in the pumpcompartment.

ELECTRICAL

4 - 29CX EXCAVATORS

AUTOMATIC POWER BOOSTCircuit Configuration

1. Main Controller2. Pressure detector P13. Pressure detector P24. Travel pilot pressure switch5. Option pilot pressure switch

6. Engine Controller7. Main relief valve8. Power Boost solenoid valve

Pressure increase in each work modeCX210/CX240

H MODES MODE 4970 → 5410 psi (8 seconds)

L MODE 4970 → 5410 (constant)AUTO MODE 4970 → 5410 (8 seconds)

case cx 210 exc trainnig service

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